Exhaust Gas Recirculation Cooler Replacement Opel Agila B

Remove

1. 1. Remove 2x wiper arm from vehicle • Remove 2x cap, 2x nut
2. 2. Remove battery from vehicle • Disconnect battery negative lead (3) – Release nut • Disconnect battery positive lead – Release cover (1) – Release nut (2) • Remove bracket from battery tray – Remove bolt (4)

3. 3. Disconnect hose (5) from mass air flow (MAF) meter (6) • Release clip
4. 4. Disconnect harness connector (3) from MAF meter
5. 5. Disconnect hose (1) from air cleaner assembly • Release from clip
6. 6. Remove air cleaner assembly (2) from vehicle • Remove 2x bolt (4) • Release 2x locator from battery tray – Pull up

7. 7. Release glow plug control unit (1) from battery tray, then move to one side • Release from 2x clip

8. 8. Remove battery tray (1) from vehicle • Remove 4x bolt

9. 9. Disconnect 2x harness connector from ECM • Pull out 2x lock (1), then release 2x clip (2)

10. 10. For left drive vehicle, release harness from ECM • Disconnect harness connector (3) from harness • Remove bracket (2) from ECM – Remove bolt (1)

11. 11. For left drive vehicle, remove bracket (2), earth lead (3) and ECM (1) from lower cowl panel • Remove 3x bolt

12. 12. For right drive vehicle, remove ECM (1) and bracket (3) from cowl panel grille • Remove 4x bolt
13. 13. For right drive vehicle, remove ECM and earth lead (2) from bracket • Remove 4x bolt

14. 14. Remove cowl grille panel (1) from vehicle • Remove 7x clip, then release 14x clip, 3x locator
15. 15. Remove windshield wiper motor (3) from vehicle • Disconnect harness connector • Remove 3x bolt (2)
16. 16. Release harness from lower cowl panel • Release clip

17. 17. Remove lower cowl panel (2) from vehicle • Remove 6x nut (1)

Important. Do not remove cap from radiator when hot

18. 18. Remove cap from radiator
19. 19. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used coolant.

20. 20. Drain cooling system • Place collecting container below • Open radiator drain plug (1) • Allow coolant to drain into collecting container • Close radiator drain plug • Remove collecting container
21. 21. Lower vehicle

22. 22. Remove heater outlet pipe with turbo pipe assembly from EGR cooler (2) • Release 5x clip, 3x bolt
23. 23. Release intake manifold elbow from intake manifold • Remove 3x bolt, clip
24. 24. Disconnect harness connector from EGR valve (1)
25. 25. Disconnect 2x hose from EGR cooler • Release 2x clip
26. 26. Remove EGR valve and cooler from cylinder head • Remove gasket • Remove 2x bolt • Release 2x clip
27. 27. Clean mating surfaces of cylinder head and EGR valve

28. 28. Remove EGR cooler from EGR valve assembly • Remove 3x bolt (2) • Remove gasket (1)
29. 29. Remove 2x coolant pipe from EGR cooler • Release 2x clip • pull off

Install

30. 30. Install 2x coolant pipe to new EGR cooler • Secure 2x clip • push on
31. 31. Install EGR cooler to EGR valve assembly • Install new gasket (1) • Install 3x bolt (2) 28 Nm

32. 32. Install EGR valve and cooler to cylinder head • Install new gasket • Install 2x bolt 28 Nm • Secure 2x clip
33. 33. Connect 2x hose to EGR cooler • Secure 2x clip
34. 34. Connect harness connector to EGR valve (1)
35. 35. Secure intake manifold elbow to intake manifold • Install 3x bolt, clip
36. 36. Install heater outlet pipe with turbo pipe assembly to EGR cooler (2) • Install 3x bolt, secure 5x clip

37. 37. Install lower cowl panel (2) to vehicle • Install 6x nut (1)

38. 38. Secure harness to lower cowl panel • Secure clip
39. 39. Install windshield wiper motor (3) to vehicle • Install 3x bolt (2) 8 Nm • Connect harness connector
40. 40. Install cowl grille panel (1) to vehicle • Secure 3x locator, 14x clip, then install 7x clip

41. 41. For right drive vehicle, install new ECM and earth lead (2) to bracket • Install 4x bolt 10 Nm
42. 42. For right drive vehicle, install ECM (1) and bracket (3) to cowl panel grille • Install 4x bolt 10 Nm

43. 43. For left drive vehicle, install ECM (1), bracket (2) and earth lead (3) to lower cowl panel • Install 3x bolt 10 Nm

44. 44. For left drive vehicle, secure harness to ECM • Install bracket (2) to ECM – Install bolt (1) 10 Nm • Connect harness connector (3) to harness

45. 45. Connect 2x harness connector to ECM • Push in 2x lock (1), then secure 2x clip (2)

46. 46. Install battery tray (1) to vehicle • Install 4x bolt

47. 47. Secure glow plug control unit (1) to battery tray • Secure 2x clip

48. 48. Install air cleaner assembly (2) to vehicle • Secure 2x locator to battery tray – Push on • Install 2x bolt (4)
49. 49. Connect hose (1) to air cleaner assembly • Secure clip
50. 50. Connect harness connector (3) to MAF meter
51. 51. Connect hose (5) to MAF meter (6) • Secure clip

52. 52. Install bracket to battery tray • Install bolt (4) • Connect battery positive lead – Secure nut (2) – Secure cover (1)
53. 53. Install battery to vehicle • Connect battery negative lead (3) – Secure nut 11 Nm

Important. Only use coolant approved by the manufacturer and ensure a concentration of 50% water and 50% anti-freeze.

54. 54. Fill coolant expansion tank with new coolant fluid up to maximum level mark
55. 55. Install cap to coolant expansion tank
56. 56. Install 2x wiper arm to vehicle • Adjust and align wiper arm • Install 2x nut 18 Nm • Install 2x cap
57. 57. Program all volatile memories – see operation “Program Volatile Memories”